Injection molded composite blank and guide

ABSTRACT

This specification discloses an article of manufacture. The article of manufacture has at least one structural blank and at least one guide. The structural blank has a plurality of oriented fiber plies in a thermoplastic matrix. The guide has a plurality of random dispersed fibers in a thermoplastic matrix. The guide is affixed to the structural blank by injection molding and over molding the guide onto the structural blank. The article of manufacture can take a number of forms for use in industries such as aircraft, automobiles, motorcycles, bicycles, trains or watercraft.

PRIORITY AND CROSS REFERENCES

This application claims priority from International Application No.PCT/US2013/033465 filed on 22 Mar. 2013, U.S. Provisional ApplicationNo. 61/615,040 filed on 23 Mar. 2012 and U.S. Provisional ApplicationNo. 61/615,000 filed on 23 Mar. 2012, the teachings of each of which areincorporated in their entirety.

BACKGROUND

Replacing metal and heavy parts with plastic parts is common. However,when the part takes on odd shapes or need structural strengthreplacement with plastic becomes more difficult. The use of fibers toreinforce the plastic is a common practice, with oriented fibers knownto be stronger than unoriented fibers.

Affixing a thermoplastic material to a support structure is also known.For example, WO 03/102387 describes an oil pan for an internalcombustion engine having a “shell of plastic material, and a supportstructure, having a plurality of perforations, that is fixedly attachedto the exterior surfaces and/or the interior surfaces of the plasticshell.” p. 1, ¶1. However, the current methods to manufacture sucharticles are considered to provide for an article that is too heavy foruse in applications, such as aircraft interiors, requiring lightweightarticles that maintain high strength in areas that are prone to failureunder stress.

One such challenging article is the seat frame used in airplanes. Seatframes must bear a large load. Imagine the frame locked to the floor,with a person sitting in it, and the person behind the seat grasping theseat and using it to assist lifting him or herself out of the seat. Theamount of torque on the support or weakest spot of the frame is quitelarge.

Many have tried to make a seat back using thermoset compositesreinforced with fibers. Thermoset composites are time consuming toprocess with low throughput and increased costs. Efforts to increase thetime have resulted in increased weight of the final part, making itunappealing to the airline industry.

WO 2010 111700 published 30 Sep. 2010 discloses one method ofincorporating oriented strength enhancing carbon fibers. This methodused a pre-formed tube of the fibers in a thermoplastic matrix, expandedthe tube in a heated mold allowing the thermoplastic to set up in the“U” shape of the seat back.

This method is expensive and overdesigns strength where strength is notneeded.

There exists therefore the need for a method of manufacturing an articlethat is lightweight, and that maintains high strength in areas that areprone to failure under stress.

SUMMARY

Disclosed herein is an article of manufacture comprising a structuralblank and at least one guide, wherein the structural blank has astructural blank length, a structural blank width and a structural blankheight wherein the structural blank height is less than or equal to thestructural blank width and the structural blank width is less than orequal to the structural blank length; and is comprised of a plurality oforiented fiber plies in a structural blank thermoplastic matrix where atleast one ply of the plurality of oriented fiber plies lies in astructural blank horizontal plane defined by the structural blank lengthand structural blank width, a structural blank top side corresponding toone side of the structural blank horizontal plane, a structural blankbottom side corresponding to the side opposite of the structural blanktop side of the structural blank horizontal plane, and at least onestructural blank guide hole passing from the structural blank top sidethrough the structural blank horizontal plane to the structural blankbottom side; the guide has a guide length, a guide width and a guideheight and is comprised of a plurality of randomly dispersed fibers in aguide thermoplastic matrix, wherein the guide is affixed to at least aportion of the structural blank top side with the guide thermoplasticmatrix surrounding the structural blank guide hole.

In one embodiment the guide is overmolded into the structural blankhole. In a further embodiment the guide is affixed to the structuralblank by melt bonding.

In one embodiment the structural blank thermoplastic matrix and theguide thermoplastic matrix may further comprise a thermoplastic selectedfrom the group consisting of polyphenylene sulphide, polyetherimide,polyetheretherketone, polyetherketoneketone, polyethylene terephthalate,polybutylene terephthalate, and polyethylene naphthalate and the guidethermoplastic matrix comprises a thermoplastic selected from the groupconsisting of polyphenylene sulphide, polyetherimide,polyetheretherketone, polyetherketoneketone, polyethylene terephthalate,polyester, polybutylene terephthalate, polyethylene naphthalate,polyethersulfone and combinations thereof.

In one embodiment, the structural blank thermoplastic matrix and theguide thermoplastic matrix comprise the same thermoplastic.

In one embodiment the oriented fiber plies of the structural blank andthe randomly dispersed fibers of the guide comprise a type of fiberselected from the group consisting of carbon fiber, glass fiber,polyaramide fiber or combinations thereof.

In one embodiment at least one type of fiber of the oriented fibers ofthe structural blank and at least one type of fiber of the randomlydispersed fibers of the guide are the same type of fibers.

In one embodiment the amount of fibers in the structural blankthermoplastic matrix is between 5% and 60% by weight of the structuralblank.

In a further embodiment the amount of fibers in the guide thermoplasticmatrix is between 5% and 60% by weight of the guide.

In one embodiment the structural blank is formed by compression moldingthe plurality of oriented fiber plies comprised of the structural blankthermoplastic matrix and oriented fibers.

In one embodiment the at least one structural blank hole is selectedfrom the group of holes consisting of a circular hole or a non-circularhole. In a further embodiment the at least one structural blank hole iscountersunk into the structural blank horizontal plane in the structuralblank top side, the structural blank bottom side, or both the structuralblank top side and the structural blank bottom side.

In one embodiment the plurality of randomly dispersed fibers of theguide are molded to a guide shape having a guide shape top side whereinthe guide shape top side corresponds to one side of a guide horizontalplane corresponding to the guide length and the guide width, and a guideshape bottom side wherein the guide shape bottom side corresponds toside opposite the guide shape top side of the guide horizontal planecorresponding to the guide length and the guide width.

In one embodiment the guide passes from the structural blank top sidethrough the structural blank hole to at least the structural blankbottom side.

In one embodiment the guide has a guide hole passing from the guideshape top side through the guide shape to the guide shape bottom side inthe same plane as the at least one structural blank hole.

In one embodiment the at least one structural blank hole comprises aplurality of structural blank reinforcing holes. In a further embodimentthe guide thermoplastic matrix passes through the plurality ofstructural blank reinforcing holes.

In one embodiment the plurality of random fibers of the guide are moldedto a first guide shape affixed to the structural blank top side and asecond guide shape affixed to the structural blank bottom side. In afurther embodiment the first guide shape and the second guide shape arethe same shape.

In one embodiment the article is void of an adhesive layer between theguide and the structural blank. In a further embodiment the structuralblank is corona treated or flame treated before over molding.

Also disclosed in this specification is an article of manufacturecomprising a “U” shaped member comprising a first leg, a second leg, atop member, and at least one leg pad up; wherein the first leg comprisesa first thermoplastic matrix comprised of randomly dispersed fiber typesand the first leg has a first leg first end which is not connected withthe top member and a first leg second end which is connected with thetop member, the second leg is comprised of a second thermoplastic matrixcomprised of randomly dispersed fiber types and the second leg has asecond leg first end which is not connected with the top member and asecond leg second end which is connected with the top member, with thetop member connected to the first leg and the second leg to form the “U”shaped member wherein the “U” shaped member has a “U” shaped memberhorizontal plane defined by the first leg, the second leg and the topmember with the “U” with the first leg having a first leg stresslocation and the second leg having a second leg stress location, and,the at least one leg pad up is comprised of oriented fiber typesoriented in a plane in a third thermoplastic matrix with the leg pad upaffixed to either the first or second leg.

In one embodiment the fiber types in the first thermoplastic matrix, thesecond thermoplastic matrix and the third thermoplastic matrix are eachselected from the group consisting of glass fibers and carbon fibers. Ina further embodiment the first and second thermoplastic matrix are thesame.

In one embodiment leg pad up is affixed to either the first leg orsecond leg at the first leg stress location or the second leg stresslocation.

In one embodiment the third thermoplastic matrix is the samethermoplastic as the first thermoplastic matrix.

In one embodiment the article of manufacture comprises a melt bondbetween the third thermoplastic matrix of the leg pad up and either thefirst thermoplastic matrix of the first leg or the second thermoplasticmatrix of the second leg.

In one embodiment the first leg, the second leg and the top member areconnected as one continuous piece.

In one embodiment the at least one leg pad up has at least one leg padup hole through and the first or second thermoplastic matrix passesthrough the at least one first leg pad up hole.

In one embodiment the at least one leg pad up is a compression moldedpart having at least one ply of oriented fibers. In another embodimentthermoplastic matrix of the first leg has been injection molded aroundthe leg pad up.

Further disclosed in this specification is a process for structurallyreinforcing a seat back, said process comprising melt bonding a leg padup comprised of oriented fibers oriented in a plane within a thirdthermoplastic to a portion of a “U” defined by a first leg comprisingrandomly dispersed fibers in a first thermoplastic matrix, a second legcomprising randomly dispersed fibers in a second thermoplastic matrix,and a top member of the seat back.

In one embodiment the melt bonding is done during the manufacture of theportion of the “U” by injection molding the first or secondthermoplastic with dispersed fibers of the portion of the “U” at theedge of or around the leg pad up.

In one embodiment the third thermoplastic of the leg pad up is the samethermoplastic as the thermoplastic used to manufacture the portion ofthe “U” to which the leg pad up is melt bonded.

In one embodiment the leg pad further comprises a hole through whichthermoplastic used to manufacture the portion of the “U” to which theleg pad up is melt bonded will flow during the injection moldingprocess.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an article of manufacture using the process describedherein.

FIG. 2 shows a structural blank used to manufacture an article using theprocess described herein.

FIG. 3 shows the structural blank having a structural blank hole.

FIG. 4 shows the structural blank countersunk around the structuralblank hole.

FIG. 5 shows the structural blank having a plurality of holes.

FIG. 6 shows an article of manufacture using the process describedherein.

FIG. 7 shows an article of manufacture using the process describedherein.

FIG. 8 shows a cut-away side view of an article of manufacture using theprocess described herein.

FIG. 9 shows a cut-away side view of an article of manufacture using theprocess described herein.

FIG. 10 shows a cut-away side view of an article of manufacture usingthe process described herein.

FIG. 11 shows a cut-away side view of an article of manufacture usingthe process described herein.

FIG. 12 shows an exemplary model of an article of manufacture using theprocess described herein.

FIG. 13 shows the exemplary model of FIG. 12 disassembled.

FIG. 14 is a depiction of blow up of an embodiment of the claimedinvention.

FIG. 15 is a cutaway view of an embodiment of the claimed invention.

FIG. 16 is a depiction of an embodiment of a seat frame.

FIG. 17 is a cutaway view of an embodiment of the claimed invention.

FIG. 18 is another depiction of an embodiment of a seat frame.

DETAILED DESCRIPTION

This specification discloses an article of manufacture (100) comprisinga structural blank (200) having a plurality of oriented fiber plies in athermoplastic matrix affixed to a guide (300, 320) having a plurality ofrandomly dispersed fibers in a thermoplastic matrix which may comprisechopped fibers. In one embodiment there is more than one guide (see forexample FIG. 1, 320A, 320B, 320C, 320D)

The article of manufacture and process to manufacture the article reliesupon the discovery that an injection moldable grade of thermoplasticcomprising randomly dispersed or chopped fibers can be affixed to athermoplastic composite having unidirectional oriented fibers in atleast one ply by injection molding techniques such as injection molding,insert molding or over molding.

The structural blank will have a structural blank length dimension(110), a structural blank width dimension (111) and a structural blankheight dimension (112). The structural blank height dimension is alsoknown as the structural blank thickness. The structural blank heightdimension will be less than or equal to the structural blank widthdimension with the structural blank width dimension less than or equalto the structural blank length dimension. The structural blank will becomprised of plies of unidirectional oriented fibers. At least one plyof the plurality of oriented fiber plies in the structural blank willlie in a horizontal plane defined by the structural blank lengthdimension and the structural blank width dimension.

Although not necessary, the structural blank (FIGS. 2, 3 and 4 (200))should have at least one hole (220) or perforation, but it is preferableto have a plurality of holes or perforations (240), at least some ofwhich serve to further affix and/or reinforce the guide (300) to thestructural blank. The at least one hole or perforation will pass throughthe horizontal plane of the structural blank from the top side of thestructural blank to the bottom side of the structural blank. Thestructural blank hole may be a circular hole or a non-circular hole,such as a slot, ellipsoid, or trapezoid shape. In one embodiment, aplurality of structural blank holes may be located along the perimeter(240) of the structural blank corresponding to the structural blanklength dimension and/or the structural blank width dimension and areused to reinforce the guide to the structural blank. In a furtherembodiment, the plurality of structural blank holes are structural blankguide holes through which the guide thermoplastic matrix passes, but arenot used to reinforce the guide to the structural blank. The structuralblank holes may also be used to create a guide ridge or rim (300).

In a preferred embodiment (FIG. 4) the structural blank hole or holesare countersunk (230) into the structural blank. The structural blankhole may be countersunk into the top side of the structural blank, thebottom side of the structural blank, or both the top side and the bottomside of the structural blank. The structural blank hole may becountersunk into the structural blank in a circular manner or anon-circular manner.

The structural blank will be made from a thermoplastic matrix materialor a thermoset. The term “thermoset” means plastic materials having athree dimensional crosslinked network resulting from the formation ofcovalent bonds between chemically reactive groups, e.g., active hydrogengroups and free isocyanate groups or oxirane groups. Thermosets may bethose known to the skilled artisan, e.g., crosslinked polyurethanes,crosslinked polyepoxides and crosslinked polyesters. Thermosets may befabricated from crosslinked polyurethanes by the art-recognized processof reaction injection molding. Reaction injection molding typicallyinvolves, as is known to the skilled artisan, injecting separately, andpreferably simultaneously, into a mold: (i) an active hydrogenfunctional component (e.g., a polyol and/or polyamine); and (ii) afunctional component that forms covalent bonds with the active hydrogenfunctional component, such as an isocyanate functional component (e.g.,a diisocyanate such as toluene diisocyanate, and/or dimmers and trimersof a diisocyanate such as toluene diisocyanate). The filled mold mayoptionally be heated to ensure and/or hasten complete reaction of theinjected components. Upon complete reaction of the injected components,the mold is opened and the molded article is removed.

The term “thermoplastic” means a plastic material or matrix that has asoftening or melting point, and is substantially free (having less than5% by weight of the plastic material as part of the thermoplasticmatrix) of a continuous phase of a three dimensional crosslinked networkresulting from the formation of covalent bonds between chemicallyreactive groups, e.g., active hydrogen groups and free isocyanategroups. The thermoplastic material may contain a dispersion of groundthermosets, but the matrix material itself will be substantially free ofthermosets.

Examples of thermoplastics from which the structural blank and the guidemay be fabricated include, but are not limited to, thermoplasticpolyphenylene sulfide, thermoplastic polyetheretherketone, thermoplasticpolyetherketoneketone, thermoplastic polyetherketoneketone,thermoplastic polyurethane, thermoplastic polyurea, thermoplasticpolyimide, thermoplastic polyamide, thermoplastic polyamideimide,thermoplastic polyester, thermoplastic polycarbonate, thermoplasticpolysulfone, thermoplastic polyketone, thermoplastic polypropylene,thermoplastic acrylonitrile-butadiene-styrene, thermoplasticpolyethersulfone and mixtures or thermoplastic compositions containingone or more thereof.

Of the thermoplastic materials from which the structural blank and theguide may be fabricated polyphenylene sulphide is preferred. The guidemay be fabricated from thermoplastic materials by the art-recognizedprocess of injection molding and over molding onto the structural blank,in which a molten stream of thermoplastic material, e.g., moltenthermoplastic polyphenylene sulphide, is injected into a mold, e.g., anoptionally heated mold. In a preferred embodiment, a plurality of guidesare continuously affixed to the structural blank from a single mold. Inone embodiment, the structural blank is made from a thermoset materialwhile the guide is made from a thermoplastic material.

The thermoplastic materials from which the structural blank may befabricated and the thermoplastic materials from which the guide may befabricated, are preferably reinforced with a material type selected fromthe group consisting of glass fibers, carbon fibers, metal fibers,polyaramide fibers, polyamide fibers and mixtures thereof. Thereinforcing fibers, and the glass fibers in particular, may have sizingson their surfaces to improve miscibility and/or adhesion to thethermoset or thermoplastic into which they are incorporated, as is knownto the skilled artisan. Carbon fibers are a preferred reinforcingmaterial in the present invention. If used, the reinforcement material,e.g., glass fibers, is typically present in the thermoset and/orthermoplastic of the structural blank in a reinforcing amount, e.g., inan amount of from 5 percent by weight to 60 percent by weight, based onthe total weight of the structural blank. If used, the reinforcementmaterial, e.g., glass fibers, is typically present in the thermoplasticof the guide in a reinforcing amount, e.g., in an amount of from 5percent by weight to 60 percent by weight, based on the total weight ofthe guide. In a preferred embodiment, the reinforcing material of thestructural blank and the reinforcing material of the guide are the samereinforcing material.

To obtain the strength required, the fibers in the structural blank arepreferably continuous fibers and oriented in different parallel planesof the structural blank. These planes are also called plies. One methodof manufacturing the thermoplastic structural blank is to take a seriesof individual plies which are thermoplastic materials having orientedfibers running their length and lay the plies one on top of the other.The oriented fibers can have a different orientation of one ply relativeto another ply. These various plies are often referred to as pre-pregsand are available on the open market, usually in rolls. Once the plieshave been laid one on top of the other, the plies are heat compressionmolded into a strong structural bond by applying heat and pressure tomelt and press the plies together. This pressing could be done to createa flat sheet from which the structural blank could be cut, or the pliescould be precut, laid into a mold and the pressure and heat applied. Acontinuous manufacturing operation of this type is described in DE4017978, the teachings of which are incorporated herein.

The oriented fiber in a ply may also be woven with fibers in the ply sothat many fibers are aligned in a first direction, the other fibers arealigned in a direction different from the first direction, but in thesame direction considered a second direction, passing over and under thefibers aligned in the first direction and are thus woven with the fibersaligned in the first direction.

The oriented fibers will form a plane within the thermoplastic matrix ofthe structural blank. If many plies of fibers are used, the plies willbe separate planes. The oriented fibers will have an orientationdirection. While the oriented fibers in one plane or ply may be rotatedor offset relative to the oriented fibers in another plane or ply, atany given point in the structural blank, the oriented fibers in one plywill not be oriented in a direction that traverses into another ply.Often times only a uni-directional orientation is needed. It is alsopossible that the thermoplastic matrix used to surround the orientedfibers may further comprise chopped or dispersed fibers as well.

The carbon fibers used to form the structural blank may have an averagefiber diameter of 4 micrometers to 12 micrometers. One suitable carbonfiber is from Zoltek Corporation of St Louis, Mo. USA, and has the tradename Panex 35. Other suitable carbon fibers are from Hexcel Corporationof Stamford, Conn. USA, and include AS4 carbon fibers and IM7 carbonfibers. The fiber volume fraction may be 0.5 to 0.7 of the compositestructural blank. In the case of nano-fibers, diameters of 2 to 12microns are typical.

The thermoplastic materials from which the guide may be fabricated areoften reinforced with a plurality of randomly dispersed fiber typesselected from the group consisting of glass fibers, carbon fiberes,metal fibers, polyamide fibers and mixtures thereof. The plurality ofrandomly dispersed fiber types may be the same type of fiber as those ofthe oriented fibers in the structural blank thermoplastic matrix. In onesuch embodiment, the randomly dispersed fibers originate as pre-pregsand are chopped or cut into smaller, randomly dispersed fibers prior tobeing introduced to the guide thermoplastic matrix.

If more bonding is needed, the structural blank can be corona treated orflame treated to modify the surface area to be more bondable with thethermoplastic of the guide. The best bond strength is expected when thethermoplastic matrix of the structural blank is the same thermoplasticmatrix as the guide. The increased strength of the assembly at therespective stress location will be in part a function of the number ofholes or perforations in the structural blank, the diameter or thicknessof the holes or perforations, countersinking the at least one structuralblank hole, and whether the material of the leg insert is corona treatedor flame treated. The strength increase will also be a function of theknown structural strength relationships of oriented fibers, the degreeof orientation, fiber choice and fiber density. Because the preferredmanufacturing technique is injection molding, over molding or insertmolding the guide is affixed to the structural blank by melt bondingduring the molding process.

This type of melt bonding occurs when the thermoplastic of the legpad-up is exposed to the molten thermoplastic of the leg or top sectionbeing injection molded, insert molded or over molded to or around theleg pad-up. For the best melt bonding, the thermoplastic materialsshould be the same. However, structurally similar materials will meltbond, but in general the melt point of the thermoplastic material of theleg pad-up should be greater or equal to the melt point of thethermoplastic of the leg or top section being injection molded, insertmolded or over molded to or around the leg pad-up.

Because the preferred manufacturing technique is overmolding the guideinto the structural blank hole (FIGS. 6-11), the guide is preferablyaffixed to the structural blank by melt bonding. In a preferredembodiment, the guide will not be affixed to the structural blank byadhesion between the guide and the structural blank, or by an adhesivelayer between the guide and the structural blank. Therefore, the articleof manufacture is void of an adhesive layer between the guide and thestructural blank. If the guide is affixed to the structural blank by anadhesion layer between the guide and the structural blank, such adhesionlayer may comprise an adhesive material such as tape or glue, welding inthe form of resistance welding, corona treating, ultrasonic welding, orcombinations thereof.

In a preferred embodiment (FIGS. 9, 14 and 15), the guide is molded to aguide shape having a guide shape length, a guide shape width (370) and aguide shape height (380). The guide shape will have a horizontal planecorresponding to the guide shape width and the guide shape length. Theguide shape will also have a guide shape top side corresponding to oneside of the guide shape horizontal plane and a guide shape bottom sidecorresponding to the side of the guide shape horizontal plane oppositefrom the guide shape top side. The guide shape may be circular ornon-circular. The structure of the guide may have numerousconfigurations or shapes. In a preferred embodiment of the presentinvention at least a portion of the guide comprises a channel having abase or bottom and side walls, each having interior surfaces whichdefine a hollow interior. The guide may also include a plurality ofreinforcing ribs (FIGS. 14 and 15, 160) located within hollow interiorof the channel. At least a portion of the reinforcing ribs are formed bymolding of the thermoplastic material so that at least a portion of theplastic material extends through at least some of the perforations inthe structural blank. These reinforcing ribs may have configurationsselected from, but not limited to, X-like configurations, zig-zagconfigurations, curved or arcuate configurations, parallelconfigurations and combinations thereof.

In one embodiment, there are two guide shapes where the second guideshape (340) has a second guide shape length, a second guide shape widthand a second guide shape height. The second guide shape will have ahorizontal plane corresponding to the second guide shape width and thesecond guide shape length. The second guide shape will also have asecond guide shape bottom side corresponding to one side of the guideshape horizontal plane and a second guide shape top side correspondingto the side of the guide shape horizontal plane opposite from the guideshape bottom side. The second guide shape may be circular ornon-circular.

In a preferred embodiment, when overmolding the guide to the structuralblank, the thermoplastic material of the guide passes from thestructural blank top side through the structural blank hole to thestructural blank bottom side. In one embodiment, the overmolding of theguide to the structural blank occurs at the perimeter of the structuralblank corresponding to the structural blank length dimension and thestructural blank width dimension wherein the guide thermoplasticmaterial passes through the plurality of structural blank holes locatedalong the perimeter of the structural blank in order to form a raisededge along the perimeter of the structural blank.

In one embodiment, the guide contains a guide hole (360) passing fromthe guide shape top side through the guide shape to the guide shapebottom side. In a preferred embodiment, the guide hole passes throughthe guide shape in the same plane as the at least one structural blankhole (FIG. 10).

FIG. 12 shows an assembled part (500). FIG. 13 shows the assembled partof FIG. 12 in disassembled form with 200A, 200B and 200C being thestructural blank of the respective members, 300A, 300B and 300C beingthe respective raised perimeter edge guide and 320A and 320C being therespective guide containing a guide hole. 400A, 400B and 400C are rodsor tubes and 510 is a stabilizer member.

The actual molding of an injection moldable material around apre-fabricated core or insert, such as a structural blank, is well knownin the art. U.S. Pat. No. 6,251,323, incorporated herein by reference,describes how to totally encapsulate the pre-fabricated material. Thebackground section of U.S. Pat. No. 6,251,323 describes various othertypes of injection molding processes to injection mold a material onto aprefabricated part, such as a structural blank.

The article of manufacture described herein can take any number offorms. By way of example, but not limitation, the article of manufacturecan be used in aircrafts, automobiles, motorcycles, bicycles, trains, orwatercraft. By way of example, but not limitation, in aircraftapplications the article of manufacture could be a seat center counsel,a seat center counsel frame, a tray table, a tray table support, a seatback frame, a seat leg, an overhead bin, an overhead bin frame, a drinkcart, a drink cart frame, a foot rest, or a foot rest support.

This specification also discloses an article of manufacture comprising alongitudinal section and at least one leg pad up wherein thelongitudinal section is injection molded and affixed to the pad up whichcontains strength reinforcing oriented fibers.

The article of manufacture comprises a single longitudinal sectionwithout adjoining structures. The longitudinal section will comprise athermoplastic matrix comprised of randomly dispersed fibers. Thelongitudinal section will also comprise at least one pad-up forincreased strength at a stress location.

In one embodiment, the longitudinal section is formed into an airplaneseat back. This general structure can be seen in FIG. 16 where 600denotes the composite seat back frame. In such an embodiment, thelongitudinal section will have a first leg section (650), a second legsection (700) and a top section (800). The first leg section will have afirst leg section length dimension (680), a first leg section widthdimension (660), a first leg section height dimension (670). The lengthdimension will be the longest dimension and is aligned with thedirection of the spine of a person sitting in the seat. The widthdimension is the dimension traveling perpendicular to the lengthdimension, lying in the “U” structure horizontal plane defined by thefirst leg section, the second leg section and the top section whichconnects or joins the first and second leg sections. The first andsecond leg section horizontal dimensions are perpendicular to the “U”structure horizontal plane.

The top section could be straight piece, or a curved piece thattransitions from the second end of the first leg section, running in the“U” structure horizontal plane and then transitions into the second endof the second leg section.

It is preferred that the first leg section, the second leg section andthe top section are all one single molded part and are connected by meltflow or melt bonding of the thermoplastic matrix material. In thisinstance, the first leg section, the second leg section and the topsection are all comprised of the same thermoplastic matrix.

For clarity, the first leg section further will have a first leg sectionfirst end (610). The second leg section is usually of similar, or evenlike dimensional design as the first leg section. The second leg sectionwill have a second leg section length dimension, a second leg sectionwidth dimension, a second leg section height dimension, wherein thesecond leg section length is the longest dimension of the second legsection, the second leg section further having a second leg sectionfirst end.

As mentioned earlier, the top section will have a top section lengthdimension (830), a top section width dimension (810), a top sectionheight dimension (820), with the top section connected to the first legsection second end and the second leg section second end in a “U”structure having a “U” structure horizontal plane (900) defined by thefirst leg section, the second leg section. Thus the first and second legsection, lie in the “U” structure horizontal plane.

The first leg section and second leg section will each have at least onestress location defined respectively as the first leg section stresslocation and the second leg section stress location. The stress locationof the respective leg depends upon the leg design and how the leg islocked or permanently fixed. The stress location is the point where theleg without the leg pad-up structurally fails when an increasing forceis applied to the top section when the first and second leg sections arefixed so they do not move. Structurally fails mean that the leg ispermanently distorted from its original shape, which is usually observedas a kink, a collapse, or the propagation of a crack. In general, theleg pad-up (200) should be located at the leg stress location.

The increasing force is applied perpendicular to the “U” shaped memberhorizontal plane. In a preferred embodiment, the legs are made of thesame mirror design and same dimensions and materials, so a force appliedat the middle of the top section should cause both legs to fail at thesame time insubstantially the same place. However, this is often not thecase, and the force can be varied at different points along the topsection to cause the leg of interest to fail before the other leg.Should a leg not fail, then its stress location is at the leg endfurthest from the top section.

Where the article of manufacture is an airplane seat back, the airplaneseat back can have one or more leg pad-ups as shown in FIG. 5, known asa “pad-up” in molding parlance. The first leg section will have a firstleg section pad-up (200A) with a first leg section pad-up lengthdimension (110), a first leg section pad-up width dimension (112), and afirst leg section pad-up height dimension (111) affixed to the first legsection inside the first leg section and located at the first legsection stress location with the first leg section pad-up lengthdimension corresponding to the first leg section length dimension, thefirst leg section pad-up height dimension corresponding to the first legsection height dimension, and the first leg section width dimensioncorresponding to the first leg section width dimension.

Most likely there will be a second leg section pad-up (200C) having asecond leg section pad-up length dimension, a second leg section pad-upwidth dimension, and a second leg section pad-up height dimensionconnected with the second leg section inside the second leg section andlocated at the second leg section stress location with the second legsection pad-up length dimension corresponding to the second leg sectionlength dimension, the second leg section pad-up height dimensioncorresponding to the second leg section height dimension, and the secondleg section width dimension corresponding to the second leg sectionwidth dimension;

The first leg section pad-up is comprised of a first thermoplastic andoriented fibers and the second leg section pad-up is comprised of asecond thermoplastic and oriented fibers.

This could be the inside or outside of the leg. During molding formationof the leg, a portion of the thermoplastic material of the leg willextend or pass through at least some of perforations (220) embedding theedges of the perforations in the thermoplastic material extending therethrough, thereby fixedly attaching the leg pad-up to the leg as well asmelt bonding the thermoplastic of the leg pad-up with the thermoplasticmatrix of the leg. In another embodiment, the thermoplastic will moldthrough the perforations or apertures and form and bond with thethermoplastic material on the other side of the leg pad-up, thereby morepermanently affixing or connecting the leg pad-up to the legthermoplastic.

When the leg pad-up is affixed to a leg the fibers are aligned so theplane lies substantially parallel to the side of the leg formed from thefirst end to the second end. Substantially parallel means that the planeis not perpendicular to the side of the leg, or does not pass throughboth sides of the leg in a perpendicular manner.

In a preferred embodiment the leg pad-up(s) will have at least one holeor perforation and the ribs will pass through holes of the leg pad-upand be molded around the inserted leg pad-up. The pad-up hole oraperture does not have to be round, but could be of hexagonal or evenrectangular or square design to prevent turning about the hole.

It should be clear to one of ordinary skill how using the much strongerdirectionally oriented fibers of the leg pad-up placed at and into areasof stress locations allows for an injection molded seat back to bequickly made. The invention is not limited to the embodiments disclosedbut to all equivalents using the principles taught herein.

FIG. 18 shows how the leg pad-up 200A, 200B, or top section pad-up 200Cmay be affixed to the outside of the leg or top section. In thisinstance the pad-up is placed on the outside of the wall of the mold andthe thermoplastic matrix injection molded or over molded onto andthrough any holes of the leg pad-up.

Because this invention may use thermoplastics that are inherently flameretardant, the use of additional flame retardants is not considerednecessary. Thus, the article of this invention is halogen free, meaningthat the total amount of halogens which are not present as catalyst forthe thermoplastic material, is less than 1% by weight of the totalcomposition halogens. The amount of halogen is the amount of material ashalogen, not the amount of Halogen compound.

Although particular embodiments of the invention have been describedherein, it will be understood that the invention is not limitedcorrespondingly in scope, but includes all changes and modificationscoming within the spirit and terms of claims appended hereto.Particularly, the current invention is not limited to an airplane seatback frame, but encompasses any structural component which can be madeof thermoplastic materials requiring lighter weight and increasedstrength.

Where the current invention is in the form of an airplane seat back, thestructure of the legs may have numerous configurations or shapes. In apreferred embodiment of the present invention at least a portion of theleg comprises, a channel having a base or bottom and side walls, eachhaving interior surfaces which define a hollow interior.

We claim:
 1. An article of manufacture comprising a thermoplasticinjection molded guide melt bonded to a thermoplastic structural blank,wherein the thermoplastic injection molded guide comprises a guidethermoplastic matrix, the thermoplastic structural blank has astructural blank length, a structural blank width, and a structuralblank height wherein the structural blank height is less than or equalto the structural blank width and the structural blank width is lessthan or equal to the structural blank length, and the thermoplasticstructural blank comprises; at least one ply containing a plurality oforiented continuous fibers in a structural blank thermoplastic matrixwherein the plurality of oriented continuous fibers are selected fromthe group consisting of unidirectional oriented fibers and wovenoriented fibers, and the at least one ply lies in a structural blankhorizontal plane defined by the structural blank length and thestructural blank width, a structural blank top side corresponding to oneside of the structural blank horizontal plane, and a structural blankbottom side corresponding to the side opposite of the structural blanktop side of the structural blank horizontal plane, and the thermoplasticinjection molded guide is molded to at least a portion of the structuralblank top side, around the structural blank height and to at least aportion of the structural blank bottom side, and a guide hole runningthrough at least a portion of the guide in a plane perpendicular withthe at least one ply containing a plurality of oriented continuousfibers, wherein the guide hole is within a perimeter of the structuralblank horizontal plane, the guide material does not touch an internaledge of an optional hole in the thermoplastic structural blank, and thethermoplastic injection molded guide further comprises a plurality ofrandomly dispersed fibers in the guide thermoplastic matrix.
 2. Thearticle of manufacture of claim 1, wherein the randomly dispersed fibersin the guide thermoplastic matrix comprise a type of fiber selected fromthe group consisting of carbon fiber, glass fiber, polyaramide fiber orcombinations thereof.
 3. The article of manufacture of claim 1, whereinthe oriented continuous fibers in the structural blank thermoplasticmatrix comprise a type of fiber selected from the group consisting ofcarbon fiber, glass fiber, polyaramide fiber or combinations thereof. 4.The article of manufacture of claim 1, wherein the amount of orientedcontinuous fibers in the structural blank thermoplastic matrix isbetween 5% and 60% by weight of the structural blank.
 5. The article ofmanufacture of claim 1, wherein the amount of randomly dispersed fibersin the guide thermoplastic matrix is between 5% and 60% by weight of thestructural blank.
 6. The article of manufacture of claim 1, wherein thestructural blank thermoplastic matrix comprises a thermoplastic selectedfrom the group consisting of polyphenylene sulphide, polyetherimide,polyetheretherketone, polyetherketoneketone, polyethylene terephthalate,polybutylene terephthalate, polyethylene naphthalate, polyethersulfoneand combinations thereof.
 7. The article of manufacture of claim 6,wherein the guide thermoplastic matrix comprises a thermoplasticselected from the group consisting of polyphenylene sulphide,polyetherimide, polyetheretherketone, polyetherketoneketone,polyethylene terephthalate, polyester, polybutylene terephthalate,polyethylene naphthalate, polyethersulfone and combinations thereof. 8.The article of manufacture of claim 7, wherein the structural blankthermoplastic matrix and the guide thermoplastic matrix comprise thesame type of thermoplastic.
 9. The article of manufacture of claim 7,wherein the structural blank thermoplastic matrix comprises a differentthermoplastic than the guide thermoplastic matrix.
 10. The article ofmanufacture of claim 1, wherein the article is void of an adhesive layerbetween the guide and the structural blank.
 11. A process for producingthe article of manufacture of claim 1 comprising the structural blankand the guide, said process comprising the steps of: A) manufacturingthe structural blank by laying the at least one ply of oriented fibersin a structural blank thermoplastic matrix on top of one another andheat compression molding said at least one ply to form the structuralblank, B) injection molding the guide comprising a guide thermoplasticmatrix and a plurality of randomly dispersed fibers onto the structuralblank wherein the guide is affixed to the structural blank by meltbonding.
 12. The process of claim 11, further comprising the step ofcorona treating the structural blank to modify the surface area to bemore bondable with the thermoplastic of the guide prior to injectionmolding the guide to the structural blank.
 13. The process of claim 11,further comprising the step of flame treating the structural blank tomodify the surface area to be more bondable with the thermoplastic ofthe guide prior to injection molding the guide to the structural blank.